Shoe With Custom Molded Foot Plate and Method of Making

ABSTRACT

The present invention is a shoe that incorporates a custom insole and method of making the shoe with insole, where a press molded foot plate, the insole, is formed from a positive mold of a foot with the foot at an elevated height corresponding to a height of a high heel shoe, the press molded foot plate extends the length of the shoe to receive the shoe uppers, the shoe outer sole and the desired heel. Alternatively, the shoe, with the incorporated insole, can be a non-customized product that would allow for mass production of the shoe with insole.

This Application is a continuation-in-part of U.S. patent application Ser. No. 12/190,579, filed Aug. 12, 2008 which claims benefit of U.S. Provisional Patent Application 60/955,571, filed Aug. 13, 2007, the disclosures of which are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

There are two types of custom-made foot orthotics in existence, a “custom functional foot orthotic” and a “custom accommodative foot orthotic.” A “custom functional foot orthotic” can be described as a shoe insert that is custom designed to realign an individual's foot, so that the foot functions in a more optimal position during weight bearing activities. A “custom accommodative foot orthotic” is a custom made shoe insert that relieves pressure by padding a painful or injured area(s) on the bottom of the foot (e.g. bony prominences and their side effects). When necessary, properties from both types of orthotics can be combined to produce optimal results and address all problematic areas.

The scientific literature documents that a custom foot orthotic, when used with any type of shoe gear, at any heel height, can effectively alleviate foot, ankle, knee, and even back pain. Despite their effectiveness, the desire to use such a device is often met with resistance. There are several reasons for this. First, functional orthotics takes up a lot of room in the shoes in which they are placed. This often allows the device only to be worn with comfort in a wide, bulky type shoe, such as a sneaker. Second, if a bulky insert is placed in a narrow shoe, shoe deformation can result. This deformation can result in a poorly fitting shoe that may lead to further problems. Third, custom functional foot orthotics generally must be used in closed shoes. Closed shoes allow the orthotics to remain within the shoes and decrease malpositioning of the device. Currently existing orthotics do not work well with open shoes such as sandals or open back shoes.

Custom foot orthotic manufacturers have attempted to develop several methods to resolve these problems. The first was the production of “custom dress orthotics”. These devices are thin, less supportive, often made only partial foot length and are, consequently, less effective than the custom functional foot orthotic. Custom dress orthotics merely act as arch supports in contrast to the more bulky, but more effective, custom functional foot orthotic. Because these devices are typically only manufactured in partial foot lengths, they often move around within the shoe and are not held properly against the bottom of the foot. This leads to discomfort. Additional foot discomfort is reported by women who commonly complain of pain in the balls of their feet when wearing high heeled shoes. High heeled shoes concentrate the weight bearing portion of the foot on the balls of the feet. A dress orthotic cannot adequately alleviate this complaint because a downward sliding motion of the dress orthotic occurs. This sliding does not allow for the dress orthotic to re-distribute some of the body weight from the ball of the foot to the heel. Also of importance custom dress orthotics are manufactured so that they best function in shoes with a predetermined heel height. As the heel height of a shoe increases, the actual foot arch height is also increased. Consequently, a custom dress orthotic that is manufactured for a shoe of a low heel height will result in a custom foot orthotic with a low arch height. If this device is then transferred to, and used in, a shoe of a higher heel height, the arch area of the custom foot orthotic will not adequately support the newly heightened position of the foot arch. On the contrary, if a custom foot orthotic was manufactured for use in a shoe with a high heel height and if it is transferred to a low arch shoe, the arch height of the orthotic would be too high for the newly positioned arch height of the foot.

Second, manufacturers have suggested that functional foot orthotics can be made to fit into specific brands of pre-made shoes that have thick, removable insoles. An example of these shoes would be the brand marketed under the name “Naot”® (Naot Footwear, Naot Mordechai, Israel). “Naot” produces various types of shoes including sandals, casual dress shoes, and sportswear shoes. Even though using this type of shoe does provide for a slightly greater variety of shoe selection, significant shortcomings are still noted. This type of shoe was not designed for use with a custom foot orthotic. They were designed to be used with a thick, cork, insole with which the shoe is manufactured. As a consequence, a functional foot orthotic manufactured for this type of shoe often has to be modified so that the length, width and height of the device is equal to that of the non-functional, thick insole that came with the shoe. This compromise can result in a custom functional foot orthotic that does not function optimally. Furthermore, since these are manufactured to accommodate the pre-made bulky insole, the shoes themselves are often bulky in the sole region and not aesthetically appealing. Dress type shoes are generally not made by these companies for this reason.

In order to fully understand the present invention, the three basic components of a conventional shoe must first be described. A shoe basically consists of an upper, an insole, and an outsole. An upper is the portion of a shoe that covers the foot. An insole consists of a layer of material that sits inside the shoe and creates a layer between the sole and the wearer's foot. If removable, this is the portion of the shoe that is replaced by the custom functional foot orthotic. The outsole is the exposed portion of the sole that is in contact with the ground.

BRIEF SUMMARY OF THE INVENTION

As discussed in the background of the invention section, a custom functional foot orthotic that is placed over, or replaces the insole of a non-custom made shoe often results in resistance to using the device because of a variety of reasons that include, but are not limited to: 1.) taking up to much room in a shoe; 2.) causing shoe deformation; 3.) Generally requiring the use of closed shoes; 4.) sliding of the “custom dress orthotics” within the shoe; 5.) Not functioning optimally when switched to a shoe of a different heel height; 6.) Pre-made, Naot type shoes being too bulky and not aesthetically appealing for dress; 7.) Having to compromise function of the orthotic so that it can fit in a specific shoe.

One embodiment of the present inventions, which includes the presented device (the shoe), as well as the method for producing the device, addresses and resolves all of the above issues regarding the resistance to using custom functional foot orthotics, by producing an entire “custom functional shoe”. The key factor that distinguishes this shoe from a conventional shoe is a new custom molded foot plate (“the custom foot plate”). The “custom foot plate” is a solid unit that consists of two components, a custom functional foot orthotic and a “forefoot extension”. In essence, the “custom foot plate” is a device that extends the full length of the shoe. This invention provides a full length platform to which the basic components of the conventional shoe can be attached, those being the upper, insole and outsole. The “custom foot plate” is the insole and is positioned above the outsole portion of the shoe.

In one embodiment, being the “custom functional shoe” which contains the “custom foot plate,” a custom functional foot orthotic is no longer placed in the shoe. The custom functional orthotic is now incorporated into the shoe. This eliminates the need to place any space occupying object within the shoe. As a result, shoe deformation that occurs with the use of custom functional foot orthotics will no longer occur. Because the custom functional foot orthotic is no longer a separate entity from the shoe, it can no longer cause discomfort from sliding around in the shoe. Regarding high heeled shoes, weight can now be adequately redistributed from the ball of the foot to the heel. As a result, the “custom functional shoe” alleviates pain in the ball of the foot that is commonly present in wearer's of conventional high heeled shoes. Moreover, any type of shoe can be constructed with this method, including strapped shoes, open shoes, closed shoes etc. Because the functional foot plate is made specifically for the heel height of the shoe that it is incorporated in, the custom functional foot orthotic portion will always function optimally. The foot plate is thin, because it is press molded, thus shoes made with this device do not have to be bulky and therefore are more aesthetically appealing. The functional portion of the orthotic no longer has to be altered so that it fits into a shoe.

In one embodiment, the invention is a custom shoe sole having a press molded foot plate formed from a positive mold of a foot. The press molded foot plate extends substantially the length of said foot.

Preferably, the custom press molded foot plate is formed of a heat moldable material Suitable materials may include, but would not be limited to polypropylene, polyethylene, acrylic, graphite, fiberglass, carbon fiber material, a composite material Ethylene-vinyl acetate (EVA), polyethylene, polyethylene foams, closed cell cross-linked polyethylene foam, cork, or combinations thereof.

In a preferred embodiment, the custom press molded foot plate has a uniform thickness.

The present invention also encompasses a shoe with a custom sole having:

a. a press molded foot plate;

b. uppers;

c. an outer sole; and

d. optionally, a heel.

The shoe has a press molded foot plate which is formed of a heat moldable material.

The shoe can have uppers positioned to avoid pressure on parts of a foot expressing podiatric pathology or anomaly.

The shoe can have a heel that is relatively flat in relation to an outer sole of said shoe or a low to high heel up to about 4-5 inches.

The shoe has uppers and outer sole attached to the molded foot plate. The press molded foot plate is the inner sole of said shoe.

The shoe may have a heel. If a heel is desired, it is also attached to the press molded foot plate.

Also contemplated is a method of making a shoe having the steps of:

a. forming a negative cast of a foot;

b. casting a positive mold from said negative cast;

c. adding a forefoot extension forming structure to said positive mold;

d. placing said positive mold on a vacuum forming base plate;

e. covering said positive mold with a moldable material;

f. placing a vacuum mold head over said positive mold with said moldable material;

g. press molding said moldable material to form a custom foot plate;

h. removing said custom foot plate from upon said positive mold;

i. cutting said custom foot plate to a desired shape; and

j. attaching uppers and outer sole to said custom foot plate;

wherein said custom foot plate is the inner sole of said shoe.

Embodiments in the present invention may be described as follows:

1. Negative Impression and Positive Mold Formation:

A desired shoe style and heel height are first selected. If using plaster of Paris rolls, or fiberglass rolls as casting material, the foot is held at the same heel height as the selected shoe. This is accomplished with a block (heel riser), or any other appropriate device, which is placed under the heel region of the foot. The casting material is applied to the foot as a slipper type cast. The foot and leg are then placed into the same position they would be in as if statically standing in the selected shoe. The casting material is allowed to set while the foot and leg are held in the position that was described. The formed negative cast mold is then removed from the foot. Liquid molding material, such as plaster of Paris is poured into the negative mold and allowed to set. This will form the positive mold. Once set, the negative cast mold is separated from the positive cast mold. Note that any of the modifications used in the art of foot orthotic manufacturing can be applied to biomechanically correct the negative or positive molds.

2. Method of Adding Described “Forefoot Extension”:

A pre-formed forefoot extension casting apparatus or mold is then attached to the front of the positive mold or casting. Note that this apparatus should resemble the pattern and size of the forefoot region of the sole of the selected shoe. The positive mold is then placed in the same position that the foot was held in during production of the negative cast before pouring the mold. Hence, the same heel riser is used to elevate the heel of the positive mold. The mold is poured and allowed to set while maintained in the described position. This addition, the “forefoot extension”, elongates the orthotic portion of the foot plate so that it is the entire length of the shoe sole. Furthermore, the “forefoot extension” will allow for the forefoot, mainly the ball and toe portion of the foot, to rest on a flat surface when standing. Note that any functional or accommodative modifications can also be added to the “forefoot extension”.

3. Vacuum Pressing Positive Mold with Added Forefoot Extension to Manufacture the “Custom Foot Plate:”

The positive mold with added “forefoot extension” is then placed in a vacuum press machine. A sheet of material large enough for formation of a footplate, such as polypropylene is heated to the temperature which is recommended, by the supply company, for molding. The recommended degree of temperature is material specific and is common knowledge in the art of orthotic making. The heated sheet of material is then placed over the positive mold and vacuum pressed. When set, the newly formed ‘custom foot plate” (pressed polypropylene in this example) is separated from the positive casting.

4. Method of Trimming Excess Material from the “Custom Foot Plate” to Fit Selected Shoe:

The excess material is cut from the edges of the “custom foot plates”. A grinding wheel is then used to form the “custom foot plate” into the desired shape. Note that a pre-made template, which resembles the shape of a tracing of the sole of the selected shoe, can be temporarily adhered to the foot plate and allow for rapid grinding of the “custom foot plate” into the desired shape. Note that the described template would have to be constructed of a material that does not grind as easily as the material that the foot plate is made of (e.g. metal sheet).

5. Shoe Assembly:

Pre-fabricated or customized uppers, insoles, soles, and heels will be attached to the “custom foot plate”. A rigid shank can be added to the custom foot plate. The “custom foot plate” is incorporated into the shoe as an inner sole. It may be held between the upper cushioning material and the sole portion of the shoe. The thin layer of cushioning that overlies the custom molded foot plate is preferably non-slip, is attached to the top part (part that sits against the plantar aspect of the foot) of the foot plate. The uppers (any type . . . straps, enclosed etc.) are adhered to the “custom foot plate” with or without the use of a last. Note that the placement of the uppers can be modified so that they do not rest against painful areas, e.g. straps can be placed to avoid pushing on a bunion. Note that the desired tightness of the uppers can be pre-determined by trial measurements made prior to shoe construction, or during shoe construction with the use of a shoe last. This can be accomplished placing a template that resembles the sole of the selected shoe, against the foot. Upper sole placement and taughtness can be pre-determined in this way. The heel is then attached to the “custom foot plate”.

The outsole material is then adhered to the under surface (the part that faces the ground) of the “custom foot plate”, and if desired, to the heel as well. The final product is then complete.

Any podiatric pathologies or anomalies which may be treated or ameliorated with custom functional or accommodating foot orthotics may be incorporated into the custom molded foot plate of the present invention.

In another embodiment, the shoe includes an incorporated insole that is pre-formed to closely conform to a wearer's foot as described above with the insole adjusted for the heel height, but is not custom made for a particular wearer's foot. This allows for mass production of shoes with insoles made according to the present invention there the insole is shaped based on an elevated heel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is side cut away of a foot in a mold.

FIG. 2 is a side cut away of the mold after a foot is removed.

FIG. 3 is side cut away of the mold removed from a casting.

FIG. 4 is a side cut away of the casing removed from the mold.

FIG. 5 is side cut away of a foot in a mold.

FIG. 6 is a side cut away of the mold after a foot is removed.

FIG. 7 is side cut away of a foot in a mold.

FIG. 8 is a side cut away of the mold after a foot is removed.

FIG. 9 is a side cut away of a casting positioned on a vacuum mold.

FIG. 10 is a side cut away of vacuum mold with shoe base plate material on a casting.

FIG. 11 is a side cut away of shoe base plate material formed around a casting.

FIG. 12 is a side cut away of shoe base plate material formed around a casting that has been trimmed.

FIG. 13 is a side cut away of the shoe base plate material with shoe uppers in place.

FIG. 14 is a side cut away of a low heel shoe having base plate material with shoe uppers in place.

FIG. 15 is a side cut away of a high heel shoe having base plate material with straps in place.

FIG. 16 is a top view of the molded foot plate having regions of different densities.

FIG. 17 is a top is a top view of the molded foot plate having regions of different densities.

FIG. 18 is a side cut away of a foot having a bony prominence being cast.

FIG. 19 is a side cut away of the casting with forefoot extension mold positioned by the forefoot.

FIG. 20 is a side view of a foot in a shoe with an elevated heel (shoe shown in cross section to expose foot) and the insole of the present invention conforming to the arch when the heel is elevated.

FIG. 21 is a side view of a foot in a shoe with an elevated heel (shoe shown in cross section to expose foot)and a conventional insole that does not conform to the arch when the heel is elevated.

FIG. 22A another diagram of shoe 60 from FIG. 20, is a side view of a foot in a shoe with an elevated heel (shoe shown in cross section to expose foot) and the insole of the present invention conforming to the arch when the heel is elevated and demonstrative vectors indicating direction of force exerted on the foot from the weight of a person standing and upward force exerted on the foot.

FIG. 22B is a cross section along section line A-A from FIG. 22A looking down on the foot and showing distribution of weight along the bottom of the foot.

FIG. 23A another diagram of shoe 60 from FIG. 21 is a side view of a foot in a shoe with an elevated heel (shoe shown in cross section to expose foot) and a conventional insole that does not conform to the arch when the heel is elevated and demonstrative vectors indicating direction of force exerted on the foot from the weight of a person standing and upward force exerted on the foot.

FIG. 23B is a cross section along section line B-B from FIG. 23A looking down on the foot and showing distribution of weight along the bottom of the foot.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention relates to the formation of a custom footplate. In one embodiment, the invention relates to the custom footplate and subsequent incorporation of the custom footplate into the fabrication of a shoe.

A casting mold 1 is filled with casting material 2 that will form an impression when a foot 3 is placed therein. When foot 3 is removed, foot cast cavity 4 in the shape of foot 3 is formed.

A casting material 5 is placed into cavity 4 to form a positive mold 6.

A casting with a low heel is formed, as shown in FIG. 5, by placing a low heel riser 7 in casting mold 1 before foot 3 is inserted therein. Cavity 8 is for casting a positive mold to be used in a low heel shoe. Typically, a low heel shoe has a heel height of about 1½ to 2 inches and lower.

A casting with a high heel is formed, as shown in FIG. 7, by placing a high heel riser 9 in casting mold 1 before foot 3 is inserted therein. Cavity 10 is for casting a positive mold to be used in a high heel shoe. Typically, a high heel shoe has a heel height of about 1½ to 2 inches and higher.

Negative castings, as are commonly known, are used to form positive molds used in fabricating the custom molded foot plate of the present invention.

Although positive mold 6 is referenced herein, it is contemplated that castings formed from low heel cavity 8 or high heel cavity 10 may be used similarly.

Referring to FIGS. 9 and 10, positive mold 6 is placed on a vacuum forming mold base 11. Moldable footplate material 12, typically provided as a planer sheet, is placed over positive mold 6. Positive mold 6 is then covered with vacuum mold head 13. Material 12 is press molded to form unfinished foot plate 14 corresponding in shape to positive mold 6. The process of press molding is carried out by those procedures as are commonly known in the art. Vacuum mold head 13 is removed and the resultant unfinished foot plate 14 formed from the press molding of material 12 is removed. Unfinished foot plate 14 is then trimmed on all sides to form custom molded foot plate 15. Custom molded foot plate 15 is of size and shape, after trimming, to be incorporated into the fabrication of a shoe. Unlike orthotics, which are placed in a shoe on top of an existing inner shoe sole, custom molded foot plate 15 is the inner sole of the shoe.

As seen in FIGS. 13 through 15, shoe uppers 16 outer sole 40, and any desired heels if any, are constructed and arranged such that they attach directly to custom molded foot plate 15 by any acceptable means. Attachment of uppers 16, 17 or 23 and outer sole 40 to custom molded foot plate 15 may include use of but not limited to, adhesive, sewing or stitching and any other means as commonly known which would securely attach uppers and outer sole 40 to custom molded foot plate 15. As depicted in FIGS. 13, 14, and 15, each shoe 20, 21, and 22 has a custom molded foot plate 15 fabricated as described herein.

Uppers 16 for flat shoe 20, uppers 17 for low heel height shoe 21, or uppers 23 for high heel shoe 22, are attached to custom molded foot plate 15 to complete the shoe structure. Uppers 16, 17 or 23 may be attached to custom molded foot plate 15 of any shoe at any desired heel height.

As discussed above, moldable footplate material 12 is positioned on positive mold 6. Moldable footplate material 12 is heated if needed. Positive mold 6 is positioned between a vacuum forming mold base 11 and a vacuum mold head 13. Vacuum forming mold base 11 and a vacuum mold head 13 are brought together to form unfinished foot plate 14 that is produced by press molding as is commonly known. The present invention uses a press molding process to form custom molded foot plate 15, as an advantageous technique to use in the formation of custom molded foot plate 15. Press molding, unlike previous techniques such as, but not limited to injection molding, provides the advantage that press molding is simpler, less expensive, and allows the sole thickness and uniformity may be more tightly controlled. Press molded articles typically maintain a uniform thickness relative to the thickness of the substrate subjected to the press molding process. The control of thickness and uniformity is desirable when forming custom molded foot plate 15 such that custom molded foot plate 15 does not become prohibitively bulky or heavy.

The custom molded foot plate 15 of the present invention may be formed of any suitable material. Suitable materials for standard shoes may include but would not be limited to, polypropylene, polyethylene, acrylic, graphite, fiberglass, carbon fiber material, a composite material, or combinations thereof. Suitable materials are any materials that are able to be used in the press molding process. Said materials should be thin, durable, stiff, and heat moldable. In a preferred embodiment, custom molded foot plate 15 would be covered with a thin layer of cushioning, on either or both sides, such as foam and the like as is commonly done in the manufacture of shoes.

For athletic shoes to be constructed, custom molded foot plate 15 may be made of a material providing a greater cushioning to a user. Examples of materials suitable for a custom molded foot plate in an athletic shoe would include, but would not be limited to, polypropylene, polyethylene, acrylic, graphite, fiberglass, carbon fiber material, a composite material, Ethylene-vinyl acetate (EVA), Nickelplast™ (a combination of ethylene vinyl acetate and polyethylene, available from Alimed, Inc., Dedham, Mass.), polyethylene foams, PLASTAZOTE® (Closed cell cross-linked polyethylene foam, available from Zotefoams, PLC, Surrey, England), cork, or combinations thereof.

The different suitable materials for custom molded foot plate 15 in both standard and athletic shoes can be used by themselves or as a combination. For example, a standard shoe custom molded foot plate 15 may be formed of a combination of polypropylene, polyethylene, and acrylic. An example of a custom molded foot plate 15 for an athletic shoe may include a combination of EVA and polyethylene foams. These examples are for illustrative purposes only and not intended to limit the combinations of materials available to for the custom molded foot plate 15 of the present invention.

Alternatively, any combination of any suitable moldable materials may be used to produce custom molded foot plate 15 of the present invention. It is known that many of the suitable materials for forming custom molded foot plate 15 of the present invention have different densities. A custom molded foot plate 15 may be constructed and arranged such that custom molded foot plate 15 prevents or inhibits undesirable motions. For example, as shown in FIG. 16, if a person has a flat foot, a denser material 31 can be placed on the medial portion of custom molded foot plate 15, and a less dense material 30 can be placed on the lateral portion of custom molded foot plate 15. Placement of materials having different densities in custom molded foot plate 15 would prevent the foot from flattening in an undesired manner. Additionally, denser material 33 may be placed by the posterior lateral heel region, and less dense material 32 is placed along the remaining portion of custom molded foot plate 15, as shown in FIG. 17. The placement of more dense and less dense materials is incorporated into custom molded foot plate 15 during the press molding process. This would encompass using two or more materials covering positive mold 6 prior to press molding custom molded foot plate 15. The general concept of constructing and arranging a sole with different densities is already used in various running shoes to prevent foot pronation. The shoes with soles of varying densities to control foot pronation are called motion controlled shoes. The custom molded foot plate 15 of the present invention has further improved on motion controlled shoes by providing a custom molded foot plate 15 that can be customized in any manner used to customize foot orthotics. The custom molded foot plate 15 of the present invention is used to treat any other foot pathology that would benefit from the use of a prescription foot orthotic.

In a preferred embodiment, a negative mold is formed in any manner as is known. In one manner of forming a negative mold, a cavity 4 is formed by stepping into casting material 2, as depicted in FIGS. 1 and 2. The foot is pushed into moldable casting material and leaves an indentation.

A negative mold may be formed by plaster or fiberglass casting in which the foot is wrapped in a plaster or fiberglass bandage. The bandage is allowed to dry and harden forming a negative cast. Liquid plaster or any acceptable casting media is poured into the negative cast to form a positive cast or positive mold. A custom molded foot plate 15 is then formed from this positive cast.

Laser imaging, as is commonly know in the art, may also be used to create custom foot molds for use in fabricating articles of the present invention. TracerCad® (The Ohio Willow Wood Co., Mt Sterling, Ohio) and Foot Fax-SL® (Amfit, Inc., Vancouver, Wash.) are two examples of commercially available laser scanners that can scan the foot. The foot is scanned, the scan is transmitted to a milling machine and the milling machine cuts a positive mold from a solid. The solid may be wood, plastic, or any material that may be milled by milling machines as are commonly known.

Positive mold 6 may be cast in a manner for producing a custom molded foot plate 15 that will be used in a shoe without an elevated heel. If desired, a negative mold 8 may be cast using a low heel riser 7, or negative mold 10 may be cast using a high heel riser 9. In using either a low heel riser 7, or a high heel riser 9, negative mold cavity 8 or 10 respectively is cast such that the arch height of custom molded foot plate 15 is correctly positioned in relation to the desired heel height. It is important to cast negative mold 8 or 10 at the heel height that will ultimately be used in the finished shoe because the arch height of a foot is increased as the heel height increases. Formation of a positive mold 6 as shown in FIG. 18 may be cast with plate 37 such that resultant footplate 15 will impart force on the forefoot extension area 28 in the custom molded foot plate 15 after press molding.

The forefoot extension area 28 is formed as described in the summary of the invention and provides a flat surface for the foot to rest upon and completes the full length and shape of the custom molded foot plate 15. The forefoot extension 28 is part of a unitary structure that is integral with the custom molded foot plate 15 of the present invention.

A mold will most closely conform to the sole of the foot when the mold is taken at the heel height that will be used. A mold that is taken of a foot without an elevated heel will create a cast that has an inaccurate arch height when incorporated into a shoe with an elevated heel. Conversely, a mold that is cast from a foot at a heel height higher than will be used will create an arch height that is ineffectively high. There is a need for casting a mold at the same height in which heels will be used. As the heel of the foot is raised off the ground, the height of the arch of the foot increases proportionally. It is imperative that the casting of the foot plate 15 occur at the desired heel height such that the sole of the foot has continual contact with the upper portion of custom molded foot plate 15. When negative mold (any of cavities 4, 8, or 10) is cast at the desired heel height of a finished shoe, the negative mold will be used to create custom molded foot plate 15 with a more secure and contoured fit of foot plate 15 to an arch 25, 26 or 27 in an elevated heel shoe. The custom molded foot plate 15 formed from a cast with a heel riser equal to that of a heel in which the custom molded foot plate 15 will be used forms an inner sole that more closely conforms, and preferably exactly conforms, to the shape of the foot that made the casting and provides better support to any of the arches 25, 26 or 27.

A finished shoe has integral custom molded foot plate 15 with uppers 16, 17 or 23, heels 41 or 18, and outer sole 40 that are directly attached to said custom molded foot plate 15 to form a custom shoe. Unlike conventional orthotics, the custom molded foot plate of the present invention is not placed on top of a shoe insole, the custom molded foot plate 15 is the entire inner sole of a shoe.

The shoes of the present invention are custom made. They can be constructed and arranged to fit any foot type or deformity. For example, women with bunion deformities often have difficulty finding shoes that do not have a strap that sits over the bunion (a strap over a bunion may cause pain to the wearer). Strap 23 (upper 23) in shoes of the present invention can be positioned to avoid the bunion. Additionally, any other bony prominences in the foot can be accommodated in the custom molded foot plate 15 and in any other parts of the shoe in which accommodation would be beneficial to the wearer. Apertures can be placed in custom molded foot plate 15, as shown in FIG. 18. A bony prominence 35 may be covered with a cover 36 that will impart an aperture into negative mold (any of cavities 4, 8, or 10) that will be accommodated in custom molded foot plate 15. The cover may be any suitable cover and may include, but would not be limited to a bandage or additional casting material placed over bony prominence 35. Custom molded foot plate 15 constructed and arranged to accommodate bony prominences will ultimately result in a custom molded foot plate and ultimately finished shoe which can offload painful bony prominences on the bottom of feet. The shoe and incorporated custom molded foot plate 15 will conform to any perturbance of the foot and would not be limited to accommodating bony prominences.

In another embodiment, a physical aperture may be formed on the custom molded foot plate 15 by capturing the prominence on either the positive mold 6 or negative mold. This can be done by forming either a prominence on the positive mold before molding or an indentation on the negative mold at the desired location.

Any modifications that are commonly used in the fabrication of conventional orthotics may be used as modification in custom molded foot plate 15 of the present invention.

The shoes of the present invention can be made as wide or narrow as needed. This includes custom fit uppers 16, 17 or 23, which can be constructed as loose or tight as needed to accommodate the needs of the wearer.

With regard to high heeled shoes, as shown in FIG. 15, since the custom molded foot plate 15 is custom cast and formed at a height equal to high heel 18, a greater surface area of the sole of the foot will be in contact with custom molded foot plate 15 in comparison to conventional high heel shoes. The casting of the custom molded foot plate 15 at the height of the heels to be used forms a casting with the arch height being properly positioned for the specific heel height. FIG. 13 has interface 25 showing the entire bottom of the foot 3 in cross section, the sole, and the arch of the foot in continual and substantially or complete contact with custom molded foot plate 15 when used in flat shoe 20. FIG. 14 has interface 26 showing the sole and arch of the foot in continual and substantially or complete contact with custom molded foot plate 15 when used in low heel 41 of low heel shoe 21. FIG. 15 has interface 27 showing the sole and arch of the foot in continual and substantially or complete contact with custom molded foot plate 15 when used in high heel 18 of high heel shoe 22. Custom molded foot plate 15 used in high heeled shoes will distribute a person's weight (wearing the shoe) more evenly throughout the sole of the foot and the shoe resulting in a significantly decrease in the amount of pain and/or pressure that people experience in the ball of their foot, generally the area where the toes join the rest of the foot, while wearing high heeled shoes.

FIG. 19 shows positive mold 6 with heel riser 9. Forefoot extension mold 45 is filled with casting material 2. Forefoot extension mold 45 has an inner cavity to receive casting material 2 and may be shaped to conform to the type of shoe desired e.g. square toe, pointed, rounded, etc. After casting material 2 is hardened, forefoot extension mold 45 is removed and forms plate 37. Plate 37 will impart forefoot extension area 28 on the custom molded foot plate 15 after press molding. As stated above, forefoot extension area 28 is unitary, contiguous and integral with molded foot plate 15. Although FIG. 19 depicts use with heel riser 9, it is contemplated that extension mold 45 may be used with any heel riser or without a heel riser. Forefoot extension mold 45 should be positioned and filled with casting material 2 while positive mold 6 is at the heel height desired in the completed shoe. Positive mold 6 should remain at the desired heel height of the finished shoe until casting material 2 inside forefoot extension mold 45 has hardened.

Referring to FIGS. 21 and 23A, the position of foot 3 in shoe 60 (shoe 60 is shown in side view cross section) having an elevated heel 62 and a conventional sole 59 according to the prior art. FIG. 20 shows foot 3 in a shoe 60 in which insole 57 of the present invention has been placed. FIG. 21 shows conventional insole 59 placed in shoe 60. More particularly, as shown in FIGS. 21 and 23A, insole 59 does not contact the arch 50 of foot 3 when used in a shoe 60 with an elevated heel 62. The lack of contact results in a void area 25 a that is between the bottom of the foot arch 50 and the top of insole 59. The lack of contact between insole 59 and arch 50 when a person is standing in a shoe with an elevated heel has a known adverse effect on the person's foot 3 of foot discomfort as described below.

As shown in FIG. 20, the downward force from the weight of a person standing in an elevated heel shoe 60 is shown by line FW.

As is known and understood by persons skilled in the art of evaluating resultant force, when force FW is exerted by the weight of a person in a downward direction, opposing forces represented by lines FH, FC, and FB are exerted. Force line FH is force exerted upward in the region of the heel, force line FC is the upward force exerted in the center region of the foot, and force line FB is the upward force exerted in the area of the ball of the foot 54.

Each line of upward force FH, FC, and FB imparts an area outward from the center of force commonly known as a dimension. Dimension, in terms of force analysis, is the outward distance from the center of a force in which effects of force are detected. Dimension DH represents a relative length along heel 52 in all directions outward from FH in which the affects of FH are imparted. Dimension DC represents a relative length along arch 50 in all directions outward from FC in which the affects of FC are imparted. Dimension DB represents a relative length along ball area 54 in all directions outward from FB in which the affects of FB are imparted.

The resultant sum of force imparted on a surface is pressure. Pressure is typically measured in bidimentional units. In the present invention, pressure is measured in pounds per square inch (psi) or any other units of pressure measuring force per unit area.

FIGS. 22A and 22B demonstrate the resultant pressure forces 56 from a person standing in a shoe 60 with elevated heel 62 in which insole 57 of the present invention has been placed.

Custom insole 57 formed as described herein contacts and conforms to substantially all of arch 50. Note that the void 25 of FIGS. 20 and 22A is not drawn to scale and encompasses a relatively small or even no separation between the top of insole 57 and arch 50 and is much smaller than the significant amount of separation 25 a, seen in FIGS. 21 and 23A, whereby void 25 a is present between the top of insole 59 and arch 50. Because of the substantial contact between insole 57 and arch 50, Insole 57 of the embodiment of the invention shown in FIGS. 21 and 22A provides a configuration that results in increased weight distribution, as will be discussed below, throughout the sole of the foot 3 on insole 57. The sole of the foot, as is commonly known, refers generally to the underside of foot 3 and encompasses heel 52, arch 50 and ball of the foot 54.

FIG. 22B is a cross section view along section line A-A from FIG. 22A and shows resultant pressure distributed along arch area 55 and heel area 52. Thus, resultant pressure from the force FW of a person standing in shoe 60 in which insole 57 has been placed is distributed substantially throughout foot 3 as shown by shading in FIG. 22B. Heel area 52 shading is shown in darker markings to indicate the heel area.

The pressure distribution shown in FIG. 22B is a significant improvement over resultant pressure imparted when using conventional insole 59, as shown in FIGS. 23A and 23B as will be explained below.

The weight of a person standing in a shoe 60 with elevated heel 62 in which conventional insole 59 has been placed imparts resultant pressure, as seen in shading of FIG. 23B only on ball area 54 and heel support area 52. There is no distribution of pressure throughout foot 3 as shown by a lack of shading in

FIG. 23B or arch area 55 which is different than the result depicted in FIG. 22B. Because the resultant pressure, when using insole 59 is not distributed throughout foot 3, the person utilizing insole 59 typically experiences discomfort due to the concentration of pressure only in ball area 54 and heel support area 52. In an elevated heel shoe 60, the concentration of pressure is disproportionately greater on the ball of the foot 54 than heel of the foot 52.

Thus, as seen in FIG. 22B, insole 57 of the present invention results in a distribution of pressure imparted by the force of a person standing in shoe 60. The distribution of pressure is substantially throughout the sole of foot 3. Distribution of force when using insole 57 will result in reduced strain on foot 3 and increases foot comfort when wearing a shoe 60 with an elevated heel 62 and insole 57.

Thus, the custom fitted insole 57 of the present invention, which is a part of the shoe 60 provides for the custom fit and beneficial pressure distribution not found when utilizing insoles 59 of the prior art.

In another embodiment, insole 57 of the present invention is mass produced, and not customized. Insole 57 is constructed and arranged, when mass produced, such that a user can select a shoe in which insole 57 more closely conforms to the wearer's foot when compared to prior art insole 59. Thus the mass produced non-customized insole 57 are pre-formed to more closely conform to the wearer's foot when compared to prior art insole 59. The increased contact area, between the wearer's foot and insole 57, results in more surface area in which the force of body weight can be distributed, FIGS. 22 A and B, when compared to prior art, FIGS. 23 A and B. This is because the non-customized insole 57 of this embodiment is preformed based on the elevated heel height of the mass produced shoe size which incorporates this non-customized insole 57 and though not customized to the actual foot of the wearer, it is pre-shaped to a wearer's foot based on the size and the elevated heel height of the shoe.

While the invention has been described in its preferred form or embodiment with some degree of particularity, it is understood that this description has been given only by way of example and that numerous changes in the details of construction, fabrication, and use, including the combination and arrangement of parts, may be made without departing from the spirit and scope of the invention. 

1. A custom shoe insole comprising: a. a press molded foot plate formed from a positive mold of a foot, said positive mold formed with said foot at an elevated heel height corresponding to a height of an elevated heel shoe; said press molded foot plate extending substantially the length of said foot.
 2. The custom shoe insole of claim 1 wherein said press molded foot plate is formed of a heat moldable material.
 3. The custom shoe insole of claim 1 wherein said press molded foot plate is formed of polypropylene, polyethylene, acrylic, graphite, fiberglass, carbon fiber material, a composite material Ethylene-vinyl acetate (EVA), polyethylene, polyethylene foams, closed cell cross-linked polyethylene foam, cork, or combinations thereof.
 4. The custom shoe insole of claim 1 wherein said press molded foot plate has a uniform thickness.
 5. A shoe insole comprising: a. a foot plate formed to an orientation corresponding to a foot size and an orientation of a foot profile corresponding to a foot placed in an elevated heel shoe, said elevated heel shoe having a particular heel height and said foot plate orientation being that of said foot profile, wherein said foot plate orientation corresponds to either said particular heel height or a heel height range relative to said particular heel height in an elevated heel shoe; said foot plate extending substantially the length of said foot.
 6. The shoe insole of claim 5 wherein said foot plate is a press molded foot plate and formed of a heat moldable material.
 7. The shoe insole of claim 5 wherein said press molded foot plate is formed of polypropylene, polyethylene, acrylic, graphite, fiberglass, carbon fiber material, a composite material Ethylene-vinyl acetate (EVA), polyethylene, polyethylene foams, closed cell cross-linked polyethylene foam, cork, or combinations thereof.
 8. The shoe insole of claim 5 wherein said foot plate has a uniform thickness.
 9. The shoe insole of claim 5 wherein said elevated heel is a height up to about 2 inches.
 10. The shoe insole of claim 5 wherein said heel is a height up to about 4 inches.
 11. The shoe insole of claim 5 wherein said insole has a further configuration to accommodate parts of a foot expressing a podiatric pathology or anomaly.
 12. The shoe insole of claim 5, wherein said oriented to a particular heel height or heel height range corresponds to a specific heel height or corresponds to a specific heel height plus or minus 0.5 inches.
 13. A shoe having an elevated heel having an insole configured to support a foot in said shoe comprising: a. an insole being a footplate according to claim 1; b. uppers attached to said insole; c. an outer soul attached to said insole; and d. an elevated heel.
 14. The shoe of claim 13 wherein said uppers are positioned to avoid pressure on parts of a foot expressing a podiatric pathology or anomaly.
 15. The shoe of claim 13 wherein said heel is a height up to about 2 inches.
 16. The shoe of claim 13 wherein said heel is a height up to about 4 inches.
 17. A method of distributing pressure throughout the sole of a foot when a person is wearing a shoe with an elevated heel, said method comprising: a. providing an insole configured to be used in a shoe with an elevated heel height; b. placing said insole into a shoe with an elevated heel; c. placing said shoe on the foot of a user; d. standing said user in said shoe with said insole, wherein said standing in said insole results in a distribution of pressure throughout substantially all of said foot.
 18. The method of claim 17 wherein said distribution of pressure is distribution through a majority of each of a ball area of a foot, an arch area of a foot, and a heel area of a foot.
 19. The method of claim 17 wherein said providing an insole further comprises selecting an insole based on both a shoe size and heel height of a particular shoe.
 20. The method of claim 19 wherein said selecting further comprises selecting an insole corresponding to a specific heel height or an insole configured to a specific heel height plus or minus 0.5 inches.
 21. A method of making a shoe insole comprising the steps of: a. casting a mold of a foot, wherein said casting occurs with the foot with an elevated heel position; b. removing said mold from said casting; c. covering said mold with a heat moldable material; d. press molding said heat moldable material over said mold; e. trimming said press molded heat moldable material to a desired shape to form a shoe insole. 